Fueling your Dodge Durango should be simple and efficient, but it can be a real inconvenience when the capless gas tank starts causing trouble.
Whether it’s fuel spillage, a stubborn flap mechanism, or a warning light that won’t go away, these issues can disrupt your day.
Fortunately, many of these problems can be resolved with practical solutions that restore the ease and reliability of your fueling system. Let’s explore what’s behind these common challenges and how to tackle them head-on.
1. Fuel Filler Flap Mechanism Failures
If your Dodge Durango’s capless gas tank isn’t working as it should, the culprit might be the fuel filler flap. Many Durango owners, especially those with 2011–2018 models, have noticed issues where the flap doesn’t close all the way.
Dirt, grime, or even small debris can get caught in the mechanism, stopping the spring-loaded flap from sealing correctly.
Over time, the spring can weaken or break, exposing the system and causing more significant problems, like gas leaks or EVAP errors.
To tackle this, start by taking a good look inside the fuel door. Check whether the flap is snugly seated and whether anything is stuck around it.
If you spot dirt or residue, grab a soft cloth or plastic tool and gently clean the area—be careful not to scratch the flap. The spring might need replacing if the flap still won’t close or seems loose.
If so, you’ll probably need to swap out the filler neck or flap assembly to get things back to normal. Keeping the area clean can help prevent this issue from happening again.
2. Difficulty Refueling or Fuel Spillage
If you’ve ever stood at the pump battling a gas nozzle that won’t cooperate, you’re not alone.
Some Dodge Durango owners report the fuel pump clicking off repeatedly or, worse, spilling gas around the filler area. These issues often point to venting problems in the capless system or physical damage to the filler neck.
The venting system plays a key role in balancing pressure as the fuel flows in. If something’s blocking the vent, like debris or a kinked vent tube, the pump might think the tank is full when it isn’t.
To troubleshoot, start by adjusting how you insert the nozzle—sometimes, rotating it slightly or pulling it back a little can help. If that doesn’t work and the problem happens across different stations, it’s time to look under the hood.
Inspect the filler neck for visible dents or kinks that could disrupt fuel flow. If you notice damage, replacing the neck might be your best bet.
Gas spilling around the filler area is likely caused by cracks in the neck or a misaligned seal. Replacing damaged parts or reseating the assembly can often solve the issue and make refueling smooth again.
3. EVAP System and Check Engine Light (CEL) Concerns
One of the more technical challenges with the capless gas tank in a Dodge Durango is when the Check Engine Light pops on, often tied to EVAP system codes like P0456 (small leak) or P0455 (large leak).
These codes can indicate that the capless system isn’t maintaining a proper seal, which is critical for the EVAP system to work as designed.
The issue often stems from the rubber seal on the filler neck’s internal flap wearing out over time. When the seal can no longer hold pressure, the system registers it as a leak.
The first step is to scan the vehicle with an OBD-II tool to confirm the specific codes related to the EVAP system. If the filler neck is the problem, you’ll likely see one of these leak-related codes.
Resolving this issue typically involves replacing the internal flap seal or refurbishing the filler neck to restore the seal’s integrity.
Once the repair is complete, clearing the codes and driving for a while will confirm whether the fix holds up. If the CEL stays off, the system works as it should again.
4. Sensor and Latch Detection Issues
The fuel filler system sometimes sends inaccurate messages, like the “Fuel System Open” alert or “Filler Door Ajar” warning on the dashboard.
These messages can appear even when the fuel door is closed correctly, leaving drivers puzzled. The issue is often related to the filler door sensor or the connected wiring.
The most common cause is a malfunctioning sensor or damaged wiring near the filler door. Over time, the wiring harness can get pinched or frayed, particularly if it’s exposed to repetitive movements or harsh conditions. When the wiring is compromised, the sensor may incorrectly signal that the fuel door is ajar.
To troubleshoot, start by visually inspecting the area around the filler door. Look for signs of chafed wires or loose connectors. If you spot any damage, carefully repair or replace the wiring to ensure proper conductivity.
A quick swap with a new unit for a faulty sensor usually resolves the issue. Once repaired, verify that the system works by checking that the dashboard warnings are clear and that the alerts no longer reappear.
Conclusion
Capless gas tank systems, like those found in Dodge Durango models, are convenient for fueling but can occasionally present unique challenges.
Whether it’s a stubborn flap mechanism, difficulty refueling, or persistent EVAP-related warnings, these problems are usually manageable with the right approach.
By instantly tackling these issues—clearing debris, replacing a damaged component, or recalibrating the system—you can keep your fuel system operating smoothly and avoid more significant complications.
Keeping an eye on these common trouble spots can save time and ensure your Durango stays road-ready.
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